Methods and systems for detecting clamping or firing failure

• US 9,877,718 B2
• Filed: 11/23/2015
• Issued: 01/30/2018
• Est. Priority Date: 02/15/2011
• Status: Active Grant

• Current Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Original Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Inventors: Weir, David, Durant, Kevin, Flanagan, Patrick, Robinson, David
• Primary Examiner(s): Smith, Scott A.
• Application Number:
  US14/949,827
• Publication Number:
  US 20160074036A1
• Time in Patent Office: 799 Days
• Field of Search: 227 19, 2271751, 2271752, 2271761, 2271781, 2271801, 606139, 606143, 606151, 606 21
• CPC Class Codes: A61B 17/068 Surgical staplers , e.g. containing multiple staples or clampsstaplers containing only one staple A61B17/10; magazines or containers for staples A61B17/105; for performing anastomosis A61B17/115; staplers in general B25C5/00
• CPC Class Codes: A61B 17/0686 having a forming anvil staying below the tissue during stapling
• CPC Class Codes: A61B 17/072 for applying a row of staples in a single action , e.g. the staples being applied simultaneously
• CPC Class Codes: A61B 17/07207 the staples being applied sequentially
• CPC Class Codes: A61B 17/115 Staplers for performing anastomosis in a single operation
• CPC Class Codes: A61B 2017/00017 Electrical control of surgical instruments
• CPC Class Codes: A61B 2017/00115 with audible or visual output
• CPC Class Codes: A61B 2017/00398 using powered actuators, e.g. stepper motors, solenoids
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2017/07214 Stapler heads
• CPC Class Codes: A61B 2090/064 for measuring force, pressure or mechanical tension
• CPC Class Codes: A61B 2090/0811 for the position of a particular part of an instrument with respect to the rest of the instrument, e.g. position of the anvil of a stapling instrument

Abstract

Systems and methods are provided for detecting failure in clamping of a material and/or firing of a staple into a clamped material and indicating such failure to a user on a user interface. The system and methods are particularly suited for use with end effectors having closing and/or firing mechanisms coupled to an actuator. By monitoring a driving parameter of an actuator that effects the clamping and/or firing, the systems and methods provide an indication of failure in response to the monitored drive parameter. In some embodiments, an indication of failure is output when the monitored drive parameter is outside an acceptable range of desired driving parameters during clamping and/or firing. The disclosed systems and methods are particularly beneficial when used for minimally invasive surgery.

Claims

1. A method comprising:

driving an actuator of a drive system for an end effector, the end effector having a first jaw and a second jaw for clamping a material and a staple for stapling the material clamped between the first and second jaws, wherein driving the actuator to clamp moves the first jaw toward the second jaw so as to clamp the material between the first and second jaws such that a clamping force is applied and driving the actuator to staple produces a firing force so as to fire the staple into the material clamped between the first and second jaws;

continuously monitoring a drive parameter of the drive system during application of the clamping force, the firing force, or both the clamping force and the firing force;

comparing the monitored drive parameter to an acceptable range of drive parameters; and

outputting, on a user interface, an indicator for indicating success or failure of clamping or firing,

wherein the indicator is of failure when the drive parameter during clamping is outside of an acceptable range of desired drive parameters for clamping or when the drive parameter during firing is outside an acceptable range of desired drive parameters for firing.

2. The method of claim 1, wherein the indicator of failure indicates a likelihood of failure, wherein the likelihood of failure comprises a probability of failure or success.

3. The method of claim 1, wherein the method is non-surgical in nature, and wherein clamping or firing comprises clamping a compliant material or firing a fastener through a compliant material.

4. The method of claim 1, wherein clamping or firing comprises clamping a body tissue or firing a staple through the clamped body tissue.

5. The method of claim 4, wherein the tissue comprises any of skin, a bowel, a stomach, lung, or other internal body organ or structure.

6. The method of claim 1, wherein the drive parameter being within the acceptable range of drive parameters corresponds with the clamping force or the firing force being within a desired range of forces.

7. The method of claim 1, further comprising determining the acceptable range of drive parameters in response to a jaw drive system displacement adjacent the actuator.

8. The method of claim 1, wherein:

the acceptable range of drive parameters varies as a function of a displacement of a clamping or firing mechanism; and

the actuator is operatively coupled to the first jaw and the staple by the clamping or firing mechanism.

9. The method of claim 1, wherein driving the actuator effects movement of the first jaw or the staple.

10. The method of claim 1, wherein the drive parameter comprises a torque output of the actuator.

11. The method of claim 1, wherein outputting the indicator comprises generating one or more of an audio signal, a visual signal, or a sensory signal on the user interface.

12. The method of claim 1, further comprising terminating driving of the actuator before a maximum clamping time during clamping and before completing clamping in response to the drive parameter of the actuator being outside the acceptable range of drive parameters.

13. The method of claim 1, further comprising terminating application of the firing force in response to the drive parameter of the drive system being outside the acceptable range of drive parameters.

14. The method of claim 1, wherein the acceptable range of drive parameters has an upper limit and a lower limit.

15. The method of claim 14, further comprising immediately terminating the firing force when the drive parameter during firing is less than the lower limit of the acceptable range of drive parameters.

16. The method of claim 14, further comprising terminating the firing force and maintaining the clamping force, when the drive parameter during firing is greater than the upper limit of the acceptable range of drive parameters.

17. The method of claim 14, further comprising reversing a direction of the clamping force by reversing the actuator applying the clamping force, thereby unclamping the clamp, when the monitored drive parameter during clamping is less than the lower limit of the acceptable range of drive parameters.

18. The method of claim 14, wherein the acceptable range of desired drive parameters is a range of torques output from the actuator, and further comprising:

terminating the clamping force or firing force during clamping or firing when the monitored drive parameter during the clamping or firing is outside the acceptable range of drive parameters.

19. The method of claim 1, wherein the drive parameter is a displacement of the actuator, a displacement of one or more driving mechanisms coupling the drive system to the end effector, or both the displacement of the actuator and the displacement of the one or more driving mechanisms.

20. The method of claim 1, further comprising outputting the indicator of success when clamping or firing is complete.